Method of producing a rimmed diaphragm



Feb. 16, 1965 E. MONETT 3,159,394

METHOD OF PRODUCING A RIMMED DIAPHRAGM Filed May 28, 1962 I I L?INVENTOR. fDW/IRD M0NT 3,169,894 Patented Feb. 16, 196

This invention constitutes a continuation-in-part of my priorapplication Serial Number 177,892, filed March 6,

1962, and, insofar as producing a device known as a pessary isconcerned, the present showing is by way of production of devices ofthis type and kind in illustrating at least one adaptation and use of myinvention and, in reference, in the following specification, to a domebody portion, it will be understood that here this term will bedescriptive of any type and kind of flexible wall reinforcing Thisinvention relates to diaphragms having reinforcing rimmed portions,comprising a coil spring with one or more rod-like cores disposed withinthe spring and wherein the body portion of the diaphragm is generallydomeshaped in form. More particularly, the invention deals with a deviceof this type and kind, sometimes referred to as a pessary, prescribed byphysicians in the practice of birth control and, wherein, the devicesare made of numerous diameters controlled by the rimmed portion of thedevice.

Still more particularly, the invention deals with a novel method ofproducing devices of the character defined which result in production ofa high percentage output as compared with old methods.

The novel features of the invention will be best understood from thefollowing description, when taken together with the accompanyingdrawing, in which certain embodiments of the invention are disclosedand, in which, the separate parts are designated by suitable referencecharacters in each of the views and, in which:

FIG. 1 is a plan view of a device made according to my invention,indicating diagrammatically the arrangement of rods in the rim portionof the device in dotted lines.

FIG. 2 is a side view, looking generally in the direction of the arrow 2of FIG. 3', showing the device in one flexed position in full lines andin a reverse flexed position in dotted lines, the dotted line showingbeing only of the rim of the device.

FIG. 3 is a view looking generally in the direction of the arrow 3 ofFIG. 2.

FIG. 4 is a sectional view, generally similar to FIG. 5,diagrammatically illustrating the position of the parts at thecompletion of the first molding step in production of the device andshowing only a small part of the dome body portion.

FIG. 5 is a section on the line 5-5 of FIG. 1 on an enlarged scale,diagrammatically illustrating the finished device, or the final steps inproducing such device and illustrating a greater portion of the dome.

FIG. 6 is a detailed view showing a portion of the'spring only of therim in section on the line 6-6 of FIG. 4 and illustrating one end of oneof the rods inserted in the spring and diagrammatically illustrating amethod of retaining the rod against movement in the spring; and

FIG. 7 is a detailed section on the line 7- -7 of FIG. 5 taken at oneterminal end of one of the rods arranged within the spring andillustrating diagrammatically the rim enveloping the spring in section.

In the construction of devices generally of the type and kind underconsideration, extreme problems have existed over a period of many yearsin successfully producing particularly the reinforcing or rim portionsof the devices with any practical output. In other words, with knownmethods, a large majority of the products have been discarded, due toflaws in the products and, particularly, in the rimmed portions thereof.By virtue of these experiences, devices of the kind underconsideration'have necessarily been sold at high prices and this can beobviated by production of devices of the kind in question in accordancewith the method more fully hereinafter described and claimed.

In the accompanying drawings, the device comprises a dome or receptaclebody portion 10, having a rim 11. In the initial formation of the rim, arim portion, as at 11', is formed as noted in FIG. 4 and arranged withinthe rim portion is a continuous coil spring 12 of predetermineddiameter. The diameters of the springs vary in producing devices ofvarious sizes. Considering FIGS. 1 to 3, inclusive, it will appear thattwo curved or arch pin sections 13 are arranged in the coils of thespring 12 in an opposed relationship to each other. Ends 14 of thesesections are spaced to form flexible rim sections 15, in which thesprings 12 only are arranged. The pins forming the sections 13 can beformed from any suitable hardened rods definitely shaped to conform tothe diameter contour of the spring 12 employed and to maintain thiscontour in rigid state and it is preferred that, with some types ofrods,

the surfaces of these rods be chrome plated. 7

By virtue of the pin sections 13, the resulting device can be flexed inthe manner diagrammatically illustrated in FIG. 2 of the drawing and, inthis figure, one flexure is indicated in full lines and the rim portionsof the other possibue fiexure is indicated in dotted lines. In FIG. 2,the contour of the dome portion in the flexed position of the device isdiagrammatically illustrated at 10'. However, this dome portion may takeany irregular contour in the fiexure of the device. In the showing ofthe device in FIG. 3, no attempt is made to illustrate the irregularcontour of the dome portion in, out this view diagrammaticallyillustrates the positioning of the rod sections 13 in substantiallyparallel relationship to each other. This position of the device is hadby applying pressure to sides of the pin sections 13 by the fingers of ahand along the line 55 of FIG. 1 in the operation of inserting thedevice in position for use. In the flexed position of the device, asshown in FIGS. 2 and 3, the sections 15 assume the curved position, asdiagrammatically illustrated.

In production of the device in accordance with the method as disclosedin my application hereinbefore identified, the general moldingprocedures are followed, as

well as the rotation of the spring rim in moving the rimfrom theposition at 11 in FIG. 4 to the position in FIG. 5 and this method ofprocedure with the method of construction is substantially as follows.

In the present method of producing a device as illustrated in theaccompanying drawing, the springs, for use in forming the rims for thedevice and in different diameters as stated above, will have inserted inthe coils of the spring at least two pin sections positioned in themanner diagrammatically illustrated in FIG. 1 of the drawing. The pinsections will be-preferably made of a diameter to snugly or frictionallyengage the inside diameter of the coils of the spring 12 and to bedefinitely positioned and held in the spring one with relation to eacheaeaeoa other as shown in FIG. 1. However, in some instances, it-

tratethe coil spring with the pin or rod sections 13 therein and used inproducing the resulting device.

These springs 12 with pin or rod sections 13 properly positioned thereinare placed in suitable dies for molding .the dome or other body portionlit and the rim 11 around the spring, including thesections 13 therein;This moldingoperation' can be performed by the use of any type or kindof material, such as a crude rubber compound,

synthetic rubber compound, plastic compound, Hypolynl compound, siliconrubber compound or. the like and, by way of illustration of oneadaptation and use of carrying my method into eifect in producing theresulting end product, reference will be made to silicon rubbercompounds and adhesives or solvents'such, for example, as silicon rubbercements used in connection therewith.

In the initial molding operation, the'molding compound encircles thespring rim, as diagrammatically indicated at 17 in FIG. 4 of thedrawing, with a relatively thin layer or covering of. the materialaround the spring, except where this covering joins the straight wallportion 18 at the base of the dome it), namely at 19.

In carrying out the above method, it will be understood that a measuredquantity of compound employed is placed in the dies, so as to fully formthe workpiece, as noted in FIG. 4 of the drawing, leaving a minimumamount of flare on the parting line of the dies. The molding operationis conducted under high pressures and at temperatures required to formthe resulting molded workpiece, it being understood that thetemperatures will vary, depending upon the particular compound employed.The workpiece is then cured in accordance with known practices;whereupon, the final steps of producing the resulting end prodnot arecarried out substantially as follows.

The cured workpiece is then suitably trimmed and placed on a mandrelconforming to the dome portion and the wallportion18, as shown in FIG.4; whereupon, the rim, as at 11', including thespring 12 is rolledupwardly along the wall or rim facing portion 18 completingsubstantially one revolution of the spring 12 in applying the facingportion to the rim. The parts will then be brought into the positionshown in FIG. 5. In this operation, the spring 12 rotates around the pinsections 13. As a result of this operation, a more or less V-shapedannular. groove 20 is formed between part of the wall -portion18 and therolled rim 11.

The. next step in the operation is to fill the groove 20 by a spray orother injection to form a fillet 21 of the cement referred to in aplastic state, which will be wiped to form a clear fillet portion;whereupon, the device is placed upon a siutable conveyor, at least partof which is agitated vertically to cause the cement to thoroughly fillthe lower contracted portion of the grove 20; whereupon,

the cement fillet 21 is allowed to set for the required period of timeand, in this setting, the cement fillet 21 unites with all engagedsurfaces of 11 and 18 in the manner of a weld, securely retaining theparts against any possible separation and the fillet 21 will preferablybe of a color consistent'with the color of the dome ltland.

rim 11 which, in the use of silicon, will be white. Upon completion ofthese operations, the resulting end product is formed. In the use ofcertainsilicon rubber compounds, the dome portion will maintain itsrounded con-,

tour at all times when the device'is in the extended position, as shownin FIG. 1 and, in part, in FIG. 5.

As previously stated, in some instances, the frictional engagement ofthe pin sections 13 with the springs will be suificient to maintainthese sections in'the pre-set positions, as shown in PEG. 1, and it willbe understood that, in the molding operation, the compound between theterminal ends 14 of the sections 13 will, in itself, maintain thesections at all times in proper relationship to each other and this isdiagrammatically illustrated by the compound of 15 at 22 in the showingof FIG. 7 of the drawing. It will, thus, be apparent that, in thefiexure of the device, as shown in FIGS'Z and 3 of. the drawing, thereWill be no shifting of the sections 13 in the rim portion of the device;As and when the retaining elements, such as 16 in FIG. would simply be.enveloped by the rim portion of the compound used but, when theseelements are composed of silicon rubber cement, the elements will becomean integral part of the compound portion of the resulting rim 11 whichis formed. In this connection, noting FIG. 5 of the drawing, lines havebeen shown in this section to clearly illustrate arrangement of thelayers one upon the other and general contour of the fillet portion 21,which is shown in different section, notwithstanding the fact that itbecomes integralwith the rim and body portion.

While one adaptation and use of my invention has been referred to above,it will be apparent that devices of any shape and contour can be formed,including the reinforcmg rim portion and, as and when sections, such asthe sections 13, are employed, these sections can be referred to asrelatively movable sections. In the type of device disclosed, theportions of the .rim, including the sections 13, may be referred to asrelatively rigid portions, which enable the device to be flexed, in themanner diagrammatically illustrated in FIGS. 2 and 3 of the drawing.

For purposes of description, the various compounds that may be used inproducing the device may be generally said to comprise a flexiblematerial or a flexible extensible material. With devices of the type andkind herein illustrated, extensibility is sometimes required. However,withother types of devices, extensibility would be undesirable and thecompounds employed can control and regulate the production of thedesired endresult or characteristics in the body portion of the device.

. Having fully described my invention, what I claim as new and desire tosecure by Letters Patent is:

1. The method'of producing devices of the character described, whichcomprises first definitely positioning hardened pin sections in spacedopposed relationship to eachuother in the coils of a circular springutilized in forming part of a circular rim of a resulting device, moldmga body portion of the device of a rubber compound together with anintegral rim joining the body portion in afaomg portion, the rimenveloping said spring and the pin sections therein in forming aworkpiece, curing the compound of said workpiece, trimming theworkpiece,then rolling the rim to encircle the facing portion thereon, sec iringthe faced rim to the body portion by a cement n rorrning a filletbetween the faced rim and body portion in production of the resultingend product, applying the cement to a groove formed between the rim andthe body portlon of the device, evenly distributing the cement in saidgroove, and agitating the=device during part of the setting operationofthe cement.

2. The method of producing devices of the character described, whichcomprises molding a workpiece of extensible material, said workpiececomprising a dome portion, a circular rimintegral with the dome portionand formed about a circular coil spring having spaced curved rodsections arranged in opposed relation in'the coil of said springand withthe dome portion joining the rim in a rim facing portion, then curvingand trimming the WOI'lG piece, thenplacing-the workpiece on a mandrel,then rotating the rim and said spring to envelop the rim with saidfacing portion, rotating said spring around said spaced rod sections inthe rotation of said rim, then applying an annular cement fillet betweenpart of the facing portion of the rim and said dome portion inintegrally joining 6 of the drawing, are employed, these elements andfixing the rim on the dome portion, and setting said 2,475,071 7/49Young 128-127 fillet in producing the resulting end product. 2,668,3292/54 Landau 1859 2,823,669 2/58 Kunnas 128127 References Cited by theExaminer 2,916,035 12/59 Jones 128-127 UNITED STATES PATENTS 5 FOREIGNPATENTS 2,042,539 12/ 35 Schmid 128-1 7 735,692 8/55 Great Britain.2,101,255 12/37 Hay 1859 2 423 35 7 47 Waterbury 12 127 RICHARD A,GAUDET: Primary Exammer- 2,427,305 9/47 Sander et a1. 156185 JORDANFRANKLIN, RICHARD J. HOFFMAN,

2,443,943 6/48 Young 128127 10 Examiners.

1. THE METHOD OF PRODUCING DEVICES OF THE CHARACTER DESCRIBED, WHICHCOMPRISES FIRST DEFINITELY POSITIONING HARDENED PIN SECTIONS IN SPACEDOPPOSED RELATIONSHIP TO EACH OTHER IN THE COILS OF A CIRCULAR SPRINGUTILIZED IN FORMING PART OF A CIRCULAR RIM OF A RESULTING DEVICE,MOLDING A BODY PORTION OF THE DEVICE OF A RUBBER COMPOUND TOGETHER WITHAN INTEGRAL RIM JOINING THE BODY PORTION IN A FACING PORTION, THE RIMENVELOPING SAID SPRING AND THE PIN SECTION THEREIN FORMING A WORKPIECE,CURING THE COMPOUND OF SAID WORKPIECE, TRIMMING THE WORKPIECE, THENROLLING THE RIM TO ENCIRCLE THE FACING PORTION THEREON, SECURING THEFACED RIM TO THE BODY PORTION BY ACEMENT IN FORMING A FILLET BETWEEN THEFACED RIM AND BODY PORTION IN PRODUCTION OF THE RESULTING END PRODUCT,APPLYING THE CEMENT TO A GROOVE FORMED BETWEEN THE RIM AND THE BODYPORTION OF THE DEVICE, EVENLY DISTRIBUTING THE CEMENT IN SAID GROOVE,AND AGITATING THE DEVICE DURING PART OF THE SETTING OPERATION OF THECEMENT.